ELECTRONIC SMOKING ARTICLE
An electronic smoking article comprising an aerosol generator and a mechanical aerosol converter insert having the capacity to improve characteristics of aerosol produced by the aerosol generator, including sensory attributes.
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This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 61/593,004, filed on Jan. 31, 2012, the entire content of which is incorporated herein by reference thereto.SUMMARY OF SELECTED FEATURES
An electronic cigarette or cigar (collectively “electronic smoking article”) is provided which includes a heater element which vaporizes liquid material to produce an aerosol or “vapor”. In an embodiment, the heater element comprises a resistive heater coil, with a wick extending therethrough. Aerosol generated by the heater coil and wick assembly is drawn down a central channel toward the mouth end portion of the smoking article.
The electronic article preferably includes a mechanical aerosol converter (MAC) insert having a face and one or more outlets. The face and outlets of the MAC insert are mutually arranged and the face is aligned with the central channel so as to cause the aerosol to strike the face prior to it being drawn out from the article. As a result, the aerosol particle size distribution is shifted to a distribution comprising a range of smaller particles, and both the vapor phase components of the aerosol and the temperature of the aerosol are reduced. These effects and possibly others are believed to contribute to sensory attributes of reduced throat irritation, even at higher levels of nicotine content in the liquid formulation, and to improved mouth feel over aerosols of electronic smoking articles lacking a MAC insert as taught herein.
In a preferred embodiment, once the liquid of the cartridge is spent, only the first section 70 is replaced. An alternate arrangement includes a layout where the entire electronic smoking article 60 is disposed once the liquid supply is depleted. In such case the battery type and other features might be engineered for simplicity and cost-effectiveness, but generally embodies the same concepts as in the preferred embodiment in which the second section is reused and/or recharged.
In a preferred embodiment, the electronic smoking article 60 is about the same size as a conventional cigarette. In some embodiments, the electronic smoking article 60 can be about 80 mm to about 110 mm long, preferably about 80 mm to about 100 mm long and about 7 mm to about 8 mm in diameter. For example, in a preferred embodiment, the electronic smoking article is about 84 mm long and has a diameter of about 7.8 mm.
Preferably, at least one adhesive-backed label is applied to the outer tube 6, preferably about the first section 70. The label preferably completely circumscribes the electronic smoking article 60 and can be colored and/or textured to provide the look and/or feel of a traditional cigarette. The label can include holes therein which are sized and positioned so as to prevent blocking of the air inlets 44 in the outer tube 6 (or casing).
The outer tube 6 and/or the inner tube 62 may be formed of any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics or composite materials containing one or more of those materials, or thermoplastics that are suitable for food or pharmaceutical applications, for example polypropylene, polyetheretherketone (PEEK), ceramic, and polyethylene. Preferably, the material is light and non-brittle. The inner tube 62 can also include a substantially water impermeable coating.
Referring now to
The space defined between the upstream gasket 15, a downstream gasket 10 and the outer tube 6 and the inner tube 62 establish the confines of the liquid supply region 22. The liquid supply region 22 comprises a liquid material and optionally a liquid storage medium 210 operable to store the liquid material therein. The liquid storage medium 210 may comprise a winding of cotton gauze or other fibrous material about the inner tube 62.
In the preferred embodiment, the liquid supply region 22 is contained in an outer annulus 620 between inner tube 62 and outer tube 6 and between the gaskets 10 and 15. Thus, the liquid supply region 22 at least partially surrounds the central air passage 21. The heater 14 preferably extends transversely across the central channel 21 between opposing portions of the liquid supply region 22, although the teachings herein are applicable to arrangements wherein the heater 14 is oriented in the longitudinal direction instead of transversely.
Preferably, the liquid storage medium 210 is a fibrous material comprising cotton, polyethylene, polyester, rayon and combinations thereof. Preferably, the fibers have a diameter ranging in size from about 6 microns to about 15 microns (e.g., about 8 microns to about 12 microns or about 9 microns to about 11 microns). The liquid storage medium 210 can be a sintered, porous or foamed material. Also preferably, the fibers are sized to be irrespirable and can have a cross-section which has a y shape, cross shape, clover shape or any other suitable shape. In the alternative, the liquid supply region 22 may comprise a filled tank lacking a fibrous storage medium 21 and containing only liquid material.
Also preferably, the liquid material has a boiling point suitable for use in the electronic smoking article 60. If the boiling point is too high, the heater 14 will not be able to vaporize liquid in the wick 28. However, if the boiling point is too low, the liquid may vaporize even when the heater 14 is not being activated.
Preferably, the liquid material includes a tobacco-containing material including volatile tobacco flavor compounds which are released from the liquid upon heating. The liquid may also be a tobacco flavor containing material or a nicotine-containing material. Alternatively, or in addition, the liquid may include a non-tobacco material. For example, the liquid may include water, solvents, ethanol, plant extracts and natural or artificial flavors. Preferably, the liquid further includes an aerosol former. Examples of suitable aerosol formers are glycerine and propylene glycol.
In use, liquid material is transferred from the liquid supply region 22 and/or liquid storage medium 210 by capillary action at each end portion of the wick 28. In an embodiment, the heater 14 can at least partially surround a central portion of the wick 28 such that when the heater 14 is activated, the liquid in that portion of the wick 28 is vaporized by the heater 14 to form an aerosol. In other embodiments, the heater 14 can be disposed adjacent a portion of the wick without being wound about the wick. The wick 28 preferably comprises filaments having a capacity to draw a liquid, more preferably a bundle of glass (or ceramic) filaments and most preferably a bundle comprising a group of windings of glass filaments, preferably three of such windings, all which arrangements are capable of drawing liquid via capillary action via spacings between the filaments. Preferably, the wick 28 is flexible and includes three strands, each strand including a plurality of filaments. Moreover, it is noted that the end portions of the wick 28 are preferably flexible and foldable into the confines of the liquid supply region 22.
Preferably, a nose portion 81 of a downstream gasket 10 is fitted into a downstream end portion 83 of the inner tube 62. An outer perimeter 82 of the gasket 10 provides a substantially liquid-tight seal with an interior surface of the outer tube 6. Aerosol generated by the heater 14 travels from the central channel 21 and through a central channel 63 in the downstream gasket 10 and into a remaining downstream end portion of a mouth piece portion 99 of the smoking article 60. From the central channel 63 of the gasket 10, the aerosol, in substantial part, is drawn into contact with a face 102 of a mechanical aerosol converter (MAC) insert 104.
Referring now to
The transverse, annular face portion 110 of the MAC insert 104 is provided with a plurality of orifices 112, which in an embodiment comprise six circular orifices 112, each orifice having a diameter ranging from about 0.015 inch to about 0.090 inch (e.g., about 0.020 inch to about 0.040 inch or about 0.028 inch to about 0.038 inch). After contacting the face 102 of the MAC insert 104, aerosol is then drawn through the orifices 112 in the MAC insert 104, which are disposed radially about the face 102.
Although the orifices 112 are shown as extending in a longitudinal direction, all or some of them may be directed divergently so as to impart a radially outward component to the velocity to the aerosol streams as they are drawn through the MAC insert 104. The number, size and shape of the orifices can be varied in the practice of the teachings herein.
Referring now to
Referring now to
In particular and in reference to region X of
Not wishing to be bound by theory, upon striking the face 102 of the MAC insert 104, it is believed that the aerosol undergoes a transformation such as shown in region Y of
As a result of drawing the aerosol through the MAC insert 104, it has been found that the aerosol of the electronic smoking article 60 tends to be lower in temperature, to have a particle size distribution that has shifted toward a range of smaller particle sizes and that the vapor phase components as previously described are reduced. It is also believed that the MAC insert 104 increases production of core-shell particles comprising a nicotine particle surrounded by a shell of propylene glycol. These attributes and others are believed to contribute to a finding that the aerosol has acceptable sensory attributes including less throat irritation and improved sensory experience, even at higher nicotine levels in the liquid formulation. The reduced aerosol temperature is believed to improve mouth feel.
As noted, use of the MAC insert 104 tends to avoid perceived sensory deficits when elevated levels of nicotine are added to the liquid formulation of an electronic smoking article. For example, an electronic smoking article of the prior art tends to produce perceived sensations of harshness and/or irritation if the liquid formulation is modified to include nicotine at levels greater than 2% by weight. It has been found that with inclusion of a MAC insert in accordance with the teachings herein, nicotine levels in the liquid formulation can be increased up to 6% nicotine with acceptable sensory attributes. Such provides opportunity to produce an electronic smoking article 60 having high impact with little to no irritation. With inclusion of the MAC insert 104, an electronic smoking article can be constructed which provides 0.18 mg of nicotine per puff on a 10 puff basis, which provides comparable levels of nicotine when compared to traditional cigarettes, with acceptable sensory attributes.
With regard to particle size distribution, it has been found that particles size distribution of an aerosol from a smoking article lacking a MAC insert as taught herein has a bell-shaped distribution of sizes in the range of about 0.1 nanometer (nm)) to about 0.7 nm. In contrast, the particles size distribution of an aerosol from an electronic smoking article including the MAC insert as described herein has a bell-shaped distribution of sizes in the range of about 0.1 nm to about 0.6 nm, a significant decrease in particle size distribution.
It has also been found that some electronic smoking articles not including a MAC insert tend to produce aerosols having temperatures at or above 110° Celsius. In contrast, an electronic smoking article 60 as described in
Referring now to
Referring now to
The disc 122 with its central orifice 122 operates to centralize the discharge of the first MAC insert 104b before it is drawn through the second MAC insert 104a. In essence the flow-centralizing disc imparts additional compaction of the aerosol while also directing the flow against the face 102a of the second MAC insert 104a. With this arrangement, additional mechanical aerosol converting events are imparted on the aerosol so as to further enhance the beneficial aspects of reduction of aerosol particle size upon the aerosol generated by the electronic smoking article 60.
It is envisioned that the first MAC insert 104b may have orifices of the shape such as shown in
Referring now to
In a preferred embodiment, the multi-port mouth end insert 140 includes at least two diverging outlet passages 142 (e.g., preferably 2 to 10 outlet passages 142, more preferably 4 outlet passages or 3, 4, 5, 6, or more passages 142). Preferably, the outlet passages 142 are located off-axis and are angled outwardly in relation to the central channel 21 of the inner tube 62 (i.e., divergently). Also preferably, the outlets 142 are uniformly distributed about a perimeter of the insert 140 so as to substantially uniformly distribute aerosol in a smoker's mouth during use and create a greater perception of fullness in the mouth. Thus, as the aerosol passes into a smoker's mouth, the aerosol enters the mouth and moves in divergent directions so as to provide a full mouth feel. In contrast, electronic smoking articles having a single, on-axis orifice tend to direct its aerosol as single jet of greater velocity toward a more limited location within a smoker's mouth.
In addition, the multi-ported mouthpiece insert 140 and its diverging outlet passages 142 are arranged and include interior surfaces 144 such that droplets of un-aerosolized liquid material, if any, that may be entrained in the aerosol strike the interior surfaces 144 of the mouth end insert 140 and/or strike portions of walls of the diverging outlet passages 142. As a result such droplets are substantially removed or broken apart so as to enhance o\the aerosol.
In the preferred embodiment, the diverging outlet passages 142 are angled at about 5° to about 60° with respect to the longitudinal axis of the outer tube 6 so as to more completely distribute aerosol throughout a mouth of a smoker during use and to remove droplets. In a preferred embodiment, there are four diverging outlet passages 142, each at an angle of about 40° to about 50° with respect to the longitudinal axis of the outer tube 6, more preferably about 40° to about 45° and most preferably about 42°.
Preferably, each of the diverging outlet passages 142 has a diameter ranging from about 0.015 inch to about 0.090 inch (e.g., about 0.020 inch to about 0.040 inch or about 0.028 inch to about 0.038 inch). The size of the diverging outlet passages 24 and the number of diverging outlet passages 24 can be selected to adjust the resistance to draw (RTD) of the electronic smoking article 60, if desired. Moreover, the mouth end insert 8 can be formed of a polymer selected from the group consisting of low density polyethylene, high density polyethylene, polypropylene, polyvinylchloride, polyetheretherketone (PEEK) and combinations thereof. The mouth end insert 8 may also be colored if desired.
In one embodiment, shown in
As shown in
In a preferred embodiment, the interior surfaces 144 of the insert 140 may include a void disposed at the convergence of the diverging outlet passages 144.
Referring now to
Referring now to
Referring now to
Optionally, the orifices 112, 112a, 112b, 112c, 112d, 112e in the embodiments of
Optionally, as shown in
Optionally, the face 102, 102a, 102b, 102c, 102d, 102e of the MAC insert 104, 104a, 104b, 104c, 104d, 104e may be porous such that it has the capacity to collect particles through adsorption and/or absorption and in lieu of or in addition, may be concave in the upstream direction or in the downstream direction to adjust its characteristics as a mechanical aerosol converter.
Although the above teachings are with reference to a particular layout of an electronic smoking article 60, the teachings are equally applicable to any electronic smoking article whatever the configuration.
When the word “about” is used in this specification in connection with a numerical value, it is intended that the associated numerical value include a tolerance of ±10% around the stated numerical value. Moreover, when reference is made to percentages in this specification, it is intended that those percentages are based on weight, i.e., weight percentages.
Moreover, when the words “generally” and “substantially” are used in connection with geometric shapes, it is intended that precision of the geometric shape is not required but that latitude for the shape is within the scope of the disclosure. When used with geometric terms, the words “generally” and “substantially” are intended to encompass not only features which meet the strict definitions but also features which fairly approximate the strict definitions.
It will now be apparent that a new, improved, and nonobvious electronic smoking article has been described in this specification with sufficient particularity as to be understood by one of ordinary skill in the art. Moreover, it will be apparent to those skilled in the art that numerous modifications, variations, substitutions, and equivalents exist for features of the electronic smoking article which do not materially depart from the spirit and scope of the invention. Accordingly, it is expressly intended that all such modifications, variations, substitutions, and equivalents which fall within the spirit and scope of the invention as defined by the appended claims shall be embraced by the appended claims.
1. An electronic smoking article comprising:
- an outer tube extending in a longitudinal direction;
- an aerosol generator within the outer tube which produces a condensation aerosol within the outer tube; and
- a liquid supply within the outer tube delivering liquid material to the aerosol generator;
- an aerosol stream forming element within the outer tube operable to produce an aerosol stream; and
- a mechanical aerosol converter (MAC) insert arranged to impart impaction upon said aerosol stream as said aerosol is being drawn from said electronic smoking article.
2. The electronic smoking article of claim 1, wherein the aerosol stream forming element is a gasket arranged such that the aerosol is drawn through a central orifice of the gasket disposed upstream of said MAC insert and said MAC insert comprises at least one orifice and a face, said face being spaced from said central orifice, said face and said central orifice being arranged such that at least some of said aerosol stream drawn through said central orifice strikes said face, whereby a characteristic of said aerosol is altered.
3. The electronic smoking article of claim 2, wherein said MAC insert comprises a plurality of orifices disposed about said face.
4. The electronic smoking article of claim 3, wherein the plurality of orifices are disposed radially outward of said face.
5. The electronic smoking article of claim 4, wherein said face is disposed within a cylindrical body, said face is spaced from an upstream edge portion of said cylindrical body, said edge portion abutting said gasket, whereby spacing between said face and said central orifice is consistently established.
6. The electronic smoking article of claim 2, wherein the characteristic of said aerosol is at least one of aerosol temperature and particle size distribution.
7. The electronic smoking article of claim 1, further comprising:
- an inner tube within the outer tube;
- a heater located in the inner tube; and
- a wick in communication with the liquid supply and surrounded by the heater such that the wick delivers liquid material to the heater and the heater heats the liquid material to a temperature sufficient to vaporize the liquid material and form an aerosol in the inner tube, wherein the liquid supply is contained in an outer annulus between the outer tube and the inner tube.
8. The electronic smoking article of claim 2, wherein the face is porous and particles of a predetermined size are retained on the face.
9. The electronic smoking article of claim 2, wherein the face is concave.
10. The electronic smoking article of claim 2, further comprising a flow centralizing arrangement and a multi-ported mouth end insert downstream of said MAC insert, said multi-ported mouth end insert comprising at least two diverging outlet passages.
11. The electronic smoking article of claim 10, wherein said at least two diverging outlet passages are angled at about 5° to about 60° in relation to a longitudinal axis of the electronic smoking article.
12. The electronic smoking article of claim 2, comprising a pair of MAC inserts and a flow centralizing arrangement operative between said MAC inserts.
13. The electronic smoking article of claim 2, wherein said MAC insert comprises a cylindrical body and a plurality of longitudinally spaced partitions extending partially across an interior of said cylindrical body in an alternating relationship.
14. The electronic smoking article of claim 7, wherein the electronic smoking article comprises a first section attachable to a second section and wherein the wick, the heater and the liquid supply are contained in the first section and a power supply is contained in the second section.
15. The electronic smoking article of claim 7, wherein the outer tube includes is a single tube and the wick, the heater, the liquid supply and a power supply re contained in the outer tube.
16. The electronic smoking article of claim 1, further including a multi-port mouth end insert, said multi-port mouth end insert comprising at least two diverging outlet passages operable to distribute aerosol throughout a mouth of a smoker during a puff.
17. The electronic smoking article of claim 1, wherein the liquid supply has a nicotine content of greater than 2% by weight based on the weight of the liquid supply.
18. The electronic smoking article of claim 2, wherein the at least one orifice is generally round and has a diameter ranging from about 0.015 inch to about 0.090 inch.
19. The electronic smoking article of claim 2, wherein the at least one orifice is elongated, has a length ranging from about 2 mm to about 5 mm and a width ranging from about 0.5 mm to about 1 mm.
20. The electronic smoking article of claim 1, wherein the MAC insert is formed of plastic or metal foil.
21. The electronic smoking article of claim 3, wherein the MAC insert is in the form of a disk and the plurality of orifices are coplanar with the face of the MAC insert.
International Classification: A24F 47/00 (20060101);